Battery arrays, constructions and method

ABSTRACT

Disclosed is a stacked array of a plurality of thin film batteries electrically connected in a staggered configuration, where the side edges of the array preferably generally conform to an interior surface of an electronic device or component thereof in order to save space. In an embodiment, a stacked array comprises at least one battery having a single surface in contact with a plurality of batteries. In another embodiment, a shaped array of a plurality of thin film batteries electrically are connected together, whereby a plurality of batteries are arranged in a single layer on a non-rectangular substrate adjacent to one another generally in the shape of the surface of the substrate. Additionally, a thin film battery is described having at least one via through the substrate and at least one other via through an insulation layer to provide electronic connection to the battery cell.

REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority under 35 U.S.C.119(e)(I) of a provisional patent application Ser. No. 61/298,448, filedJan. 26, 2010, which is incorporated herein by reference in itsentirety.

BACKGROUND Technical Field

This invention relates to the field of thin-film solid-stateenergy-storage devices, and more specifically to applicationconfigurations of thin-film solid-state batteries.

Description of the Related Art

Electronics have been incorporated into many portable devices such ascomputers, mobile phones, tracking systems, scanners, hearing aids,remote sensors, etc. One drawback to such portable devices is the needto include the power supply with the device. Portable devices typicallyuse batteries as power supplies. Batteries must have sufficient capacityto power the device for at least the length of time the device is inuse. Sufficient battery capacity can result in a power supply that isdisproportionately heavy and/or large compared to the device.Accordingly, smaller and lighter energy storage devices (i.e., powersupplies) are desired.

One such type of an energy-storage device is a solid-state, thin-filmbattery. Examples of thin-film batteries are described in U.S. Pat. Nos.5,314,765; 5,338,625; 5,445,906; 5,512,147; 5,561,004; 5,567,210;5,569,520; 5,597,660; 5,612,152; 5,654,084; and 5,705,293, each of whichis herein incorporated by reference. U.S. Pat. No. 5,338,625 describes athin-film battery, especially a thin-film microbattery, and a method formaking same having application as a backup or first integrated powersource for electronic devices. U.S. Pat. No. 5,445,906 describes amethod and system for manufacturing a thin-film battery structure formedwith the method that utilizes a plurality of deposition stations atwhich thin battery component films are built up in sequence upon aweb-like substrate as the substrate is automatically moved through thestations.

US Patent Application Publication No. 2005/0147877 describes a thin-filmbattery such as one that includes lithium or lithium compounds connectedto an electronic circuit. An environmental barrier is deposited asalternating layers, at least one of the layers providing a smoothing,planarizing, and/or leveling physical-configuration function, and atleast one other layer providing a diffusion-barrier function.

However, due at least in part to the relatively small size, such storagedevices may not be able to provide adequate power for an associatedelectronic device. Of course multiple batteries may be connected inseries or parallel, depending on the voltage and current requirements ofa device, to increase power output over just a single battery. Suchconfigurations, though, require multiple batteries and space in a small,portable device once again becomes an issue. Accordingly, therecontinues to be a need for devices and methods that facilitate provisionof power supplies in small devices.

SUMMARY OF THE INVENTION

To address these needs, an arrangement of batteries is disclosed whichmay advantageously save space when powering an electronic device. Inparticular, a stacked array of electrically connected thin filmbatteries is provided in a staggered configuration.

The outermost points of side edges on one side of the stacked arraypreferably generally conform to an interior surface of an electronicdevice or component thereof in order to advantageously save space in thedevice. Such interior surface may be, for example, either planar orcurved. In an embodiment, the stacked array comprises at least onebattery having a single surface in contact with a plurality ofbatteries.

In another embodiment, a shaped array of a plurality of thin filmbatteries electrically connected together is provided, whereby aplurality of batteries are arranged in a single layer on anon-rectangular substrate adjacent to one another generally in the shapeof the surface of the substrate.

The present invention advantageously provides in one embodiment astacked array of batteries so that the battery array has a specializedshape, but is fabricated using individual batteries that can be readilymass produced. In another embodiment, the array of batteries is arrangedin a manner to provide excellent efficiencies in use of space, while atthe same time using individual batteries that can be readily massproduced. Thus, the present product can in one aspect provide theadvantages of economies of scale through readily manufactured individualbattery components, while at the same time providing uniquely shapedbattery arrays suitable for custom applications on a relatively smallscale. The present invention therefore provides efficiencies notavailable using conventional single battery cell custom shapemanufacture technology.

A thin film battery is also provided wherein at least one via isprovided through the substrate and at least one other via through aninsulation layer to provide electronic connection to the battery cell.This battery configuration affords particular advantage in providing abattery that can be connected to a device having unique configurationrequirements, and optionally providing an opportunity to avoid use of aseparate package for containment of the battery. Additionally, Theunique connection points of contacts for the battery enables alternativeconnection configurations of multiple batteries to be connected eitherin series or in parallel.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this application, illustrate several aspects of the inventionand together with description of the embodiments serve to explain theprinciples of the invention. A brief description of the drawings is asfollows:

FIG. 1 is an illustration of a prior art thin-film battery suitable foruse in a stacking array and method in accordance with the presentinvention.

FIG. 2 is a perspective view of an illustration of one embodiment of astacked array of thin-film batteries in accordance with the presentinvention.

FIG. 3 is a side view of an illustration of the stacked battery array ofFIG. 2 including a cross-sectional view of a device enclosure.

FIG. 4 is a side view of an illustration of a prior art single batteryand a cross-section view of a device enclosure illustrating a spacesaving feature in accordance with the present invention.

FIG. 5 is a perspective view of an illustration of a second embodimentof a stacked array of thin film batteries in accordance with the presentinvention.

FIG. 6 is a perspective view of an illustration of a third embodiment ofa stacked array of thin film batteries in accordance with the presentinvention.

FIG. 7 is a perspective view of an illustration of a fourth embodimentof a stacked array of thin film batteries in accordance with the presentinvention.

FIG. 8 is a perspective view of an illustration of a fifth embodiment ofa stacked array of thin film batteries in accordance with the presentinvention.

FIG. 9 is a flow chart illustrating one embodiment of a method inaccordance with the present invention for powering an electronic device.

FIG. 10 is a perspective view of an illustration of a sixth embodimentof a stacked array of thin film batteries in accordance with the presentinvention.

FIG. 11 is a perspective view of an illustration of a seventh embodimentof an array of thin film batteries in accordance with the presentinvention.

FIG. 12 is a perspective view of an illustration of an eighth embodimentof a stacked array of thin film batteries in accordance with the presentinvention.

FIG. 13 is a perspective view of an illustration of a ninth embodimentof an array of thin film batteries in accordance with the presentinvention.

FIG. 14 is an edge view of illustration of a tenth embodiment of astacked array of thin film batteries in accordance with the presentinvention.

FIG. 15 is a cross sectional view of a battery of the present invention.

FIG. 16 is an edge view of an illustration of a stacked array of thinfilm batteries in accordance with the present invention wired inparallel.

FIG. 17 is an edge view of an illustration of a stacked array of thinfilm batteries in accordance with the present invention wired in series.

FIG. 18 is a cross sectional view of an embodiment of a battery of thepresent invention.

DETAILED DESCRIPTION

It is to be understood that a device and method in accordance with thepresent invention includes, but is not limited to, novel combinations ofconventional components, and not just particular detailed configurationsthereof. Accordingly, the structure, methods functions, control andarrangement of conventional components and circuits have, for the mostpart, been illustrated in the drawings by readily understandable blockrepresentations and schematic diagrams, in order not to obscure thedisclosure with structural details which will be readily apparent tothose skilled in the art, having the benefit of the description herein.Further, the invention is not limited to the particular embodimentsdepicted in the exemplary diagrams, but should be construed inaccordance with the language in the claims.

In accordance with the present invention, multiple batteries ofrelatively small dimension, and having relatively flat form factor maybe arranged inside a relatively small electrical device so as to form athree dimensional volume wherein at least one surface of the volume,which surface may be defined by edges of the stacked batteries, conformsto an interior surface of the device. Such batteries may be connected inserial or parallel with each other to provide power to the electricaldevice.

FIG. 1 shows a single battery 100 of the type that may be used inaccordance with the present invention. Battery 100 is relatively smalland has a relatively flat form factor. As shown, in the embodiment ofFIG. 1 battery 100 is a rectangular box having a substantiallyrectangular upper face 112 and lower face 114 and rectangular edges. Thevertical thicknesses of batteries such as battery 100 can be extremelythin (e.g., less than about 10 microns, in some embodiments, and evenless than 4 microns in other embodiments) as compared to battery lateralwidths (e.g., 1000 microns (=1 mm) to 10,000 microns (=10 mm) in someembodiments, and up to several centimeters in other embodiments). In oneembodiment, battery 100 may include a ground connection 110 and abattery output 120 for connecting battery 100 to devices to be poweredthereby. Additionally, battery 100 may include charging circuitry (notshown) as described in co-pending U.S. patent application Ser. No.12/069,440, which is incorporated by reference herein in its entirety.If battery 100 includes such charging circuitry, battery 100 mayadditionally include a charger input 130.

Preferably, the single batteries to be used in the stacked array of thepresent invention are flexible, so that the batteries can surviveflexing motion (i.e. are still functional as batteries) during eitherassembly, placement in the environment of use, or during use.Preferably, the batteries will survive a flex equivalent to thecurvature of circle having a 20 cm diameter, more preferably equivalentto the curvature of circle having a 5 cm diameter, yet more preferablyequivalent to the curvature of circle having a 1 cm diameter, and mostpreferably equivalent to the curvature of circle having a 0.5 cmdiameter.

FIG. 2 shows a plurality of batteries 100, 200, 300, 400 and 500 of thetype shown in FIG. 1 arranged relative to each other in accordance withthe present invention. In particular, battery 100 is shown populated ona circuit board 150, which can be part of a small, electronic device(not otherwise shown in FIG. 2). The electronic device can be anyrelatively small device that requires for power more than one of thetype of batteries 100 to 500. Batteries 100 to 500 are arranged in astacked configuration or array 10 with the major faces thereof incontact with one another in a staggered configuration. The batteries 100through 500 are preferably offset from one another by a distance that ison the order of the thickness of each battery. As shown in FIG. 3, whichis a side view of the stacked arrangement of batteries 100 through 500on circuit board 150 shown in FIG. 2, this offset of each battery fromthe one just beneath it defines an imaginary boundary line 600 definedby the outermost points of side edges on one side of the stackedbatteries 100 through 500 adjacent to boundary line 600. As shown,boundary line 600 is a substantially straight line. For purposes of thepresent invention, the boundary line is a best fit of the curve of theoutermost points of the side edges of the stacked batteries. Occasionaloutliers in the battery stack are expected, and therefore the skilledartisan will understand that a substantially straight boundary linecontemplates, e.g., a 5% variance in the fit of the data points.

FIG. 3 includes a cross-section of an interior surface 710 of anelectronic device 700. Electronic device 700 may be any relatively smalldevice, such as a hearing aid or remote sensor, having an interiorsurface 710 that may be part of, for example, a casing of device 700. Asshown, surface 600 formed by batteries 100 through 500 follows thecontour of surface 710 of the electronic device so that it conforms toan interior surface of the electronic device or component thereof. Inthis way, space in the electronic device can advantageously be moreefficiently used and the overall size of the electronic device canremain smaller.

In particular, while a single battery could be used to power device 700,to provide sufficient power to device 700 such a single battery wouldlikely have to be larger than any single one of batteries 100 to 500. Ifsuch larger battery had substantially the same footprint as one ofbatteries 100 to 500 it would need to be taller and would likely bemanufactured in a standard rectangular box or disk form factor. FIG. 4illustrates such a prior art single battery 100′ mounted on circuitboard 150′ in a relatively small device 700′ having interior surface710′. As shown in FIG. 4, in order to fit battery 100′ into device 700′on circuit board 150′ battery 100′ would need to be shifted on circuitboard 150′ away from interior surface 710′. Thus, the space shown bydotted line 712 would be wasted and device 700′ might have to beenlarged to accommodate battery 100′. It would also be possible toachieve the same volume of battery 100′ by enlarging the footprintthereof and reducing the height. While this might allow circuit board100′ to be shifted back towards surface 710′, such enlarged footprintbattery would consume relatively more real estate on circuit board 150′,likely requiring it to be enlarged. It might also be possible to custommanufacture a single battery having a volume substantially that ofbattery 100′ and including a curved surface substantially in the form ofsurface 600 formed by batteries 100 to 500 (shown in FIGS. 2 and 3).However, the custom manufacture of such a battery would likely be costprohibitive and any space-saving advantages provided with respect todevice 700 would not likely transfer to other devices having differentshapes.

As mentioned above, the electronic device powered by batteries 100through 500 can be any relatively small device requiring more power thancould be provided by just a single battery of the type of batteries 100through 500. If the electrical device requires more current than couldbe provided by a single such battery, batteries 100 through 500 may beelectrically connected in parallel. If more voltage is required by theelectrical device, batteries 100 through 500 may be connected in series.

Batteries 100 through 500 may be fixed in a stack by any appropriatesystem, such as by encasing the batteries within a defined container orcasing. The batteries may optionally be friction fitted into such acontainer. Optionally, the batteries may be affixed to a bracket orother holding structure. Preferably, the batteries are fixed to eachother in the ultimately desired array. Batteries may be fixed to eachother by solder welding or by a suitable adhesive, such as a hot meltadhesive, a chemically reactive adhesive or cement (such as one or twopart adhesives including cyanoacrylates, acrylics, epoxies,polyurethanes, silicones, phenolics, polyimides, plastisols, and like)or a pressure sensitive adhesive.

FIG. 5 illustrates an alternate stacked array 15 using thin-filmbatteries 110 to 510 on circuit board 160. As shown in FIG. 5, eachbattery 210 to 510 is shifted laterally in two directions from thebattery below it. Such a stacking configuration could provide spacesaving advantages in a device having an interior surface in which twowalls slant inwards and meet at an edge. FIG. 6 illustrates anotherembodiment of a stacked array 20 including thin film batteries 120 to520 on circuit board 170. In the embodiment of FIG. 6, batteries 120 to520 are stacked such that each battery is laterally shifted and rotatedfrom the battery beneath. Such a stacking configuration couldadvantageously serve space if positioned adjacent to a curved interiorsurface of a powered device, such as a surface corresponding to theboundary line 620.

Thin film batteries stacked in accordance with the present invention mayalso be of different size. For example, FIG. 7 illustrates oneembodiment of a stacked array 30 of thin film batteries in accordancewith the present invention. Array 30 includes six rectangular, thin filmbatteries 130, 230, 330, 430, 530 and 630 stacked on a substrate 180,preferably of an electronic device (not shown) powered by thin filmbatteries 130 to 630. As shown in FIG. 7, array 30 defines athree-dimensional pyramid shape 800.

In alternative embodiments of the present invention, a thin film batterystacking configuration in accordance with the present invention mayinclude batteries having top perspective view shapes other than squareor rectangular. For example, FIG. 8 illustrates stacked array 40 of 4cylindrical thin film batteries 140, 240, 340 and 440 on substrate 190.Thin film batteries 140 to 440 are stacked to define a conical section900. Stacking arrays including batteries having other top perspectiveview shapes such as, without limitation, crescents, semi-circles,triangles, and trapezoids are also considered. FIG. 10 illustratesstacked array 1000 of five pie-shaped thin film batteries 1010, 1020,1030 and 1040 and 1050 on substrate 1060.

Stated another way, the stacked array defines a three dimensional volumeselected from various shapes that provide custom, efficient use of spaceavailable in certain electronic devices. Embodiments of the presentinvention include arrays having three dimensional volume that isselected from a pyramid shape, a truncated pyramid, a conical shape, atruncated conical shape, a rhomboid, a spherical shape, a truncatedspherical shape, an ellipsoid shape and a truncated ellipsoid shape.

For purposes of the present invention, a rhomboid is a solid figure withsix faces in which each face is a parallelogram, opposite faces in pairslie in parallel planes, and at lest one angle is oblique. Ellipsoidshapes may be, for example, selected from oblate, prolate or scaleneellipsoid shapes.

In an embodiment of the present invention, the stacked array defines athree dimensional volume that is an oblique shape, such as an obliquecylinder or an oblique hexahedron. For purposes of the presentinvention, an oblique cylinder is a shape wherein the centers of thebases of a cylinder are not aligned directly one above the other.

FIG. 9 is a flow chart illustrating one embodiment of a method 1000 inaccordance with the present invention for powering an electronic device.In step 1002, a plurality of thin film batteries are provided. Then instep 1004 the provided thin film batteries are stacked in a staggeredconfiguration to form a stacked array so that the outermost points ofside edges on one side of the stacked array generally conform to aboundary line that corresponds to an interior surface of an electronicdevice or component thereof. This boundary line is discussed above andis illustrated in FIG. 3 as boundary line 600, and FIG. 6 as boundaryline 620. For example the interior surface of the electronic device maybe a planar surface or a curved surface.

In step 1006, the plurality of thin film batteries are electricallyconnected either in series or parallel to power the electronic device.

In step 1008, the stacked array prepared in step 1004 is placed in theelectronic device or component thereof.

Optionally, step 1006 can be carried out before or after placing thestacked array in an electronic device or component thereof.

In another embodiment of the present invention, a thin film battery isprovided in a shaped array of a plurality of thin film batterieselectrically connected together, whereby a plurality of batteries arearranged in a single layer on a non-rectangular substrate adjacent toone another generally in the shape of the surface of the substrate. Inan embodiment, the batteries are arranged such that no more than about20%, and preferably no more than about 10%, of the surface of thesubstrate is exposed. Thus, as shown in FIG. 11, battery array 1100comprises thin film batteries 1110, 1120 and 1130 on substrate 1190.Substrate 1190 has a portion of the substrate surface in the shape of acircle, and additionally the substrate surface comprises an annularhole. By using substrates having non-rectangular shape, an array ofbatteries may be efficiently placed in a device or location havingstrict space requirements, thereby delivering superior amounts ofbattery power in a particular environment as compared to conventionalsingle batteries or rectangular battery arrays. Thin film batteries1110, 1120 and 1130 are specially designed in shape, and are arranged toefficiently use as much of the available surface area of the uniquelyshaped substrate as possible. Additionally, film batteries 1110, 1120and-1130 are preferably uniform in size and shape, to take advantage ofmass production efficiencies.

Alternative shapes of substrates and/or individual batteries to beplaced in an array may be used in a single layer array. FIG. 12 showsbattery array 1200 that comprises thin film batteries 1210, 1220, 1230and 1240 on substrate 1290. In this embodiment, thin batteries 1210,1220, 1230 and 1240 are rectangular in shape, and so are easily massproduced. These batteries are arranged on substrate 1290 in an efficientmanner to generally conform to the shape of the substrate surface to theextent possible given the rectangular shape. Thus, while larger amountsof the surface of substrate 1200 is exposed (i.e. is does not have abattery on the surface) as compared to battery array 1110 as shown inFIG. 11, the manufacturing and design efficiencies obtained by using amore regularly shaped thin film battery may offset the lower batterypower available for certain applications.

FIG. 13 shows battery array 1300 that comprises thin film batteries1310, 1315, 1320, 1325, 1330, 1335, 1340, 1345, and 1350 on substrate1390. In this embodiment, thin batteries 1310, 1315, 1320, 1325, 1330,1335, 1340, 1345, and 1350 are triangular in shape, and so are easilymass produced. Additionally, the triangular shaped thin film batteriescan be very efficiently laid out, particularly the triangular shapedsurface of substrate 1390.

Advantageously, various uniquely shaped substrates can be fitted withuniformly sized and shaped batteries in this manner to efficientlyutilize available surface area with mass produced thin film batteries.Both batteries and substrates having non-rectangular top perspectiveview shapes such as, without limitation, crescents, semicircles,triangles, and trapezoids are specifically contemplated. The shape ofthe battery and the shape of the substrate may be the same or different,as demonstrated in FIGS. 12 until 13.

FIG. 14 shows an edge view of a battery array 1400 of the presentinvention that comprises thin film batteries 1410, 1420, 1430, 1440, and1450 on substrate 1490. Battery 1420 has a single surface 1421 incontact with batteries 1410 and 1430. Likewise, battery 1430 has asingle surface 1431 in contact with batteries 1420 and 1440. Thisarrangement provides an efficient use of valuable “real estate” incertain device constructions, and additionally provides opportunity forefficient connectivity between batteries in order to enable connectionof the batteries in particular in series, due to proximity of thebatteries. In an embodiment, the lower row of batteries 1410, 1430 and1450 are oriented with all anodes or all cathodes on the substrate sideof the array, and the upper row of batteries 1420 and 1440 are orientedwith the opposite orientation of the lower row, thereby placing thecathodes of one row adjacent to cathodes of the other row, or the anodesof one row adjacent to the anodes of the other row. As shown, thebattery array 1400 comprises two layers of thin film batteries. An arraycomprising more than two layers, such as an array of 3, 4, 5, 6, 7 . . .10 layers and so forth wherein a plurality of batteries each have asingle surface in contact with a plurality of batteries layers isspecifically contemplated.

FIG. 16 shows an edge view of a battery array 1600 of the presentinvention that comprises thin film batteries 1610, 1620, 1630, 1640,1650 and 1660 connected in parallel. The batteries are provided withcathode connectivity on one side of the battery, and anode connectivityon the other side of the battery. As shown, the batteries are staggered,with the anodes, for example, battery 1630 in contact with an anode ofboth battery 1620 and 1640. The cathodes of batteries 1610, 1630 and1650 are in contact with conductive substrate 1680, and the cathodes ofbatteries 1620, 1640 and 1660 are in electrical contact with conductivesubstrate 1690. Conductive substrates 1680 and 1690 are in electricalcontact with device 1695 through electrical conduit 1692. The anodes areelectrically connected through electrical contact 1691, and in turn arein electrical contact with device 1695 through electrical conduit 1694.

FIG. 17 shows an edge view of a battery array 1700 of the presentinvention that comprises thin film batteries 1710, 1720, 1730, 1740,1750 and 1760 connected in series on non-conductive substrates 1780 and1790. The batteries are provided with cathode connectivity and anodeconnectivity on alternate ends of the same side of the battery. Asshown, the batteries are staggered, with the anode, for example, ofbattery 1730 being in contact with the anode of battery 1740 and thecathode of battery 1730 being in contact with the anode of battery 1720.The cathode of battery 1710 is in contact with electrical contact 1791,which in turn is in electrical contact with device 1795 throughelectrical conduit 1792. The anode of battery 1760 is in contact withelectrical contact 1793, which in turn is in electrical contact withdevice 1795 through electrical conduit 1794.

FIG. 15 shows a cross sectional view of a battery 1500 of the presentinvention, wherein at least one via is provided through the substrateand at least one other via through an insulation layer to provideelectronic connection to the battery cell. Specifically, battery 1500comprises a substrate 1590 provided with vias 1591 and 1592therethrough. The substrate is a physical structure that acts as acarrier for a battery construction. In embodiments, the substrate is abasic work piece that is transformed by various process operations intothe desired microelectronic configuration. In some embodiments,substrates include conducting material (such as copper, stainless steel,aluminum and the like), insulating material (such as sapphire, ceramic,or plastic/polymer insulators and the like), semiconducting materials(such as silicon), nonsemiconducting, or combinations of semiconductingand non-semiconducting materials. In some other embodiments, substratesinclude layered structures, such as a core sheet or piece of material(such as iron-nickel alloy and the like) chosen for its coefficient ofthermal expansion (CTE) that more closely matches the CTE of an adjacentstructure such as a silicon processor chip. In some such embodiments,such a substrate core is laminated to a sheet of material chosen forelectrical and/or thermal conductivity (such a copper, aluminum alloyand the like), which in turn is covered with layer of plastic chosen forelectrical insulation, stability, and embossing characteristics.

In some embodiments, substrate 1590 is about from about 500 microns toabout 1000 microns thick. In an embodiment, substrate 1590 is a siliconwafer of from about 500 to about 650 microns thick. In anotherembodiment, substrate 1590 includes a polymer layer (e.g., Kapton) thatis from about 1 to about 30 microns thick.

Vias 1591 and 1592 are formed in substrate 1590 in any appropriatemanner, such as by etching, masking and other photolithographictechniques, drilling for example with a laser, and the like.

Cathode material 1520 (such as lithium cobalt oxide, LiCoO₂, lithiummanganese oxide, lithium iron phosphate, lithium vanadium oxide, lithiumnickel oxide, and the like) is located on cathode current collector1510. Mixed metal oxides (for example, those that include combinationsof the above mentioned metals), such as lithium nickel cobalt oxide, canalso be used to fabricate cathodes. In embodiments of the presentinvention, cathode material 1520 has a thickness of about 1 to 3microns.

Cathode current collector 1510 is exposed to provide connectivity forelectrical connection to a device to be powered by battery 1500 (e.g. anintegrated circuit) through vias 1591 and 1592.

Anode current collector 1530 is also provided, and is made from aconductive material such as copper, aluminum, nickel, iron, gold,silver, platinum, molybdenum, titanium, manganese, metal alloys,conductive ceramics, conductive semiconductors such as heavily dopedpolycrystalline silicon, and the like. In embodiments of the presentinvention, anode current collector 1530 has a thickness of about 0.1 to1 microns, or preferably about 0.5 microns.

An anode (not shown) may optionally be provided in the battery duringinitial fabrication. In an embodiment, an anode is formed after assemblyof the battery by the first charging of the battery. In a preferredembodiment, at least one component of battery 1500 is a lithium source,and a lithium metal anode is formed that in layer of lithium metal bythe first charging of the battery. In embodiments of the presentinvention, lithium ions are intercalated into an anode structure madefrom materials susceptible to such intercalation, such as graphite.

Electrolyte layer 1550 separates the cathode material 1520 from theanode current collector 1530 (and the anode, when present). Inembodiments of the present invention, electrolyte layer 1550 has athickness of from about 0.1 to about 10 microns. In embodiments of thepresent invention, electrolyte layer 1550 has a thickness of from about1 to about 5 microns. Electrolyte layer 1550 is in physical contact withboth the cathodic components and the anodic components to allow movementof ions therebetween. An electrolyte does not conduct electrons. Anelectrolyte can be liquid. An electrolyte can also be a solid,semi-solid, or combination of a porous solid and liquid, through whichions can pass. In some embodiments the electrolyte will be substantiallychemically inert or non-reactive with regard to the ion or ions andelectrode materials that are used to generate current within a batteryor cell. Electrolyte layer 1550 may be made from any electrolytematerial, such as LiPON and the like, which can be deposited as a glassfilm or layer through which lithium ions can pass if a source of lithiumions and a destination for the lithium ions is provided. It isspecifically contemplated that electrolyte layer 1550 may comprise oneor more electrolyte materials, either blended or in two or moredistinguishable layers. An example of a preferred multilayeredelectrolyte construction is described in U.S. patent application Ser.No. 11/458,091 entitled “THIN-FILM BATTERIES WITH SOFT AND HARDELECTROLYTE LAYERS AND METHOD,” which is hereby incorporated byreference in total for all purposes.

Insulation layer 1560 is provided to protect and insulate the conductivecomponents of battery 1500.

In embodiments of the present invention, insulation layer 1560 has athickness of from about 1 to about 10 microns. Insulation layer 1560 ismade from an electrically insulating material, such as photoresist(e.g., Shipley 220 photoresist; various polyimides from HD Microsystems,such as the 2720 series, which includes 2727, 2723, 2729; the 2770series which includes 2770 and 2772; the 2730 which includes 2731 and2737; the PIX Series which includes PIX-1400, PIX-3476, PIX-S200,PIX-6400; the 2500 series, which includes 2525, 2555, 2575 and 2556; andvarious other polymeric materials such as Cyclotene product numbers3022-35, 3022-46, 3022-57 and 3022-63 from Dow Chemical Company;photodefinable silicones such as WL-5351 and WL-3010 from Dow ChemicalCompany; and UV curable epoxy such as 9001 from Dymax Corporation, orthe like. In some embodiments, insulation layer 1560 includes one ormore materials such as silicon oxide, LiPON, aluminum oxide, siliconnitride, silicon oxynitride, boron nitride, ceramic, cermet, or othermetal oxide, metal nitride, metal carbide, metal oxyboride, and/or metaloxynitride, wherein the metal is aluminum, indium, tin, indium-tin,zirconium, niobium, tantalum or other suitable metal, or other suitableelectrical insulator. An insulation layer that is made from a materialthat will be self leveling for efficient planarization is preferred. Ina preferred embodiment, the insulation layer is an organic material.

Vias 1561 and 1562 are formed in insulation layer 1560 in anyappropriate manner, such as by etching, masking and otherphotolithographic techniques, drilling for example with a laser, and thelike. Anode current collector 1530 is exposed to provide connectivityfor electrical connection to a device to be powered by battery 1500(e.g. an integrated circuit) through vias 1561 and 1562.

Battery 1500 may additionally comprise one or more passivation layers,optionally in an alternating layered configuration with insulationlayers. Batteries having alternating passivation and insulation layersare described in US Patent Publication No. US 2009/0214899 A1, and U.S.Pat. No. 7,494,742, the disclosures of which are incorporated herein byreference. Batteries of similar construction, except where the lowermostcurrent collector is exposed to provide connectivity for electricalconnection to a device to be powered by battery 1500 (e.g. an integratedcircuit) through at least one via in the substrate is expresslycontemplated. Passivation layers as described herein are made fromconductive metals, such as from a conductive material such as copper,aluminum, nickel, iron, gold, silver, platinum, molybdenum, manganese,metal alloys, conductive ceramics, conductive semiconductors such asheavily doped polycrystalline silicon, and the like. In embodiments ofthe present invention, passivation layers have a thickness of from about0.11 to about 5 microns. Passivation layers may be used to provideelectrical coupling to an anode collector or a cathode collector, asappropriate, to provide remote location of a contact pad for electricalconnection to a device to be powered by battery 1500.

The battery 1500 is preferably further provided with an encapsulatingmaterial (not shown) covering the components of the battery. Theencapsulation is desirable in order to protect the battery materialsfrom exposure to water vapor, oxygen, and other environmentalcontaminants. Lithium in particular reacts readily with other elementsand compounds. Because certain thin film battery components aresensitive to exposure to environmental elements, the batteryconstruction should be isolated from the outside world after productionof the battery. The final encapsulation material preferably is anorganic material as a silicone, polyimide, epoxy or other such polymeras discussed above. In an embodiment of the present invention,encapsulating material thickness is about 8 to 10 microns. In anembodiment of the present invention, a final outer layer is siliconnitride, at a thickness of about 0.5 to 1 microns, which providesadditional hermetic protection and is compatible with integrated circuitpackaging materials. This final layer also serves as something of aphysical barrier to abrasion and handling damage.

As shown, a plurality of vias is provided in substrate 1590 andinsulation layer 1560. In an embodiment, only one via is provided ineither and/or both substrate 1590 and insulation layer 1560. In anembodiment, two or more vias are provided in either and/or bothsubstrate 1590 and insulation layer 1560. Providing a plurality of viasin either and/or both substrate 1590 and insulation layer 1560 isadvantageous, because this affords assurance of good contact in theevent that one of the vias is unsatisfactory. Additionally, providing aplurality of vias in either and/or both substrate 1590 and insulationlayer 1560 is advantageous in providing the battery configuration asshown in FIG. 14.

FIG. 18 shows a cross sectional view of a battery 1800 of the presentinvention, wherein at least one via is provided through the substrateand at least one other via through an insulation layer to provideelectronic connection to the battery cell. Specifically, battery 1800comprises a substrate 1890 provided with vias 1891 and 1892therethrough. The substrate is a physical structure that acts as acarrier for a battery construction as described above.

Vias 1891 and 1892 are formed in substrate 1890 in any appropriatemanner, such as by etching, masking and other photolithographictechniques, drilling for example with a laser, and the like.

Cathode material 1820 (such as lithium cobalt oxide, LiCoO₂, lithiummanganese oxide, lithium iron phosphate, lithium vanadium oxide, lithiumnickel oxide, and the like) is located on substrate 1890. Optionally, aseparate cathode current collector may be provided as discussed above.

Anode current collector 1830 is also provided, and is made from aconductive material such as copper, aluminum, nickel, iron, gold,silver, platinum, molybdenum, titanium, manganese, metal alloys,conductive ceramics, conductive semiconductors such as heavily dopedpolycrystalline silicon, and the like. In embodiments of the presentinvention, anode current collector 1830 has a thickness of about 0.1 to1 microns, or preferably about 0.5 microns.

An anode (not shown) may optionally be provided in the battery duringinitial fabrication. In an embodiment, an anode is formed after assemblyof the battery the first charging of the battery. In a preferredembodiment, at least one component of battery 1800 is a lithium source,and a lithium metal anode is formed that is a layer of lithium metal bythe first charging of the battery. In embodiments of the presentinvention, lithium ions are intercalated into an anode structure madefrom materials susceptible to such intercalation, such as graphite.

Electrolyte layer 1850 separates the cathode material 1820 from theanode current collector 1830 (and the anode, when present). Inembodiments of the present invention, electrolyte layer 1850 has athickness of from about 0.1 to about 10 microns. In embodiments of thepresent invention, electrolyte layer 1850 has a thickness of from about1 to about 5 microns. Electrolyte layer 1850 is in physical contact withboth the cathodic components and the anodic components to allow movementof ions therebetween. Specific aspects of the electrolyte are asdiscussed above. In a preferred embodiment, electrolyte layer 1850 maybe made from any electrolyte material, such as LiPON and the like, whichcan be deposited as a glass film or layer through which lithium ions canpass if a source of lithium ions and a destination for the lithium ionsis provided.

A first insulative passivation layer 1860 is provided to protect andelectrically insulate the conductive components of battery 1800. A firstconductive passivation layer 1870 overlies first insulative passivationlayer 1860 and is bonded to substrate 1890 on essentially the perimeterof the battery 1800. It has been found that conductive passivationlayers, and in particular conductive passivation layers made from metal,are capable of providing excellent bonds in particular to silicon wafermaterials. In this construction, electrolyte layer 1850, cathodematerial 1820 and anode current collector 1830 are encased between firstconductive passivation layer 1870 and substrate 1890.

Vias 1861 and 1862 are formed in first passivation organic layer 1860 inany appropriate manner, such as by etching, masking and otherphotolithographic techniques, drilling for example with a laser, and thelike. Anode current collector 1830 is thus electrically connected tofirst conductive passivation layer 1870.

Second insulative passivation layer 1880 is provided to further protectand electrically insulate the conductive components of battery 1800.Second conductive passivation layer 1882 overlies second insulativepassivation layer 1880 and is bonded to first conductive passivationlayer 1870 on essentially the perimeter of the battery 1800. Because ofthis bond of second conductive passivation layer 1882 to firstconductive passivation layer 1870, the negative electrical connection ofbattery 1800 to a device to be powered may optionally be made at anylocation on second conductive passivation layer 1882. In a preferredembodiment, separate contact pads 1884 and/or 1886 may be formed so thatelectrical connection (e.g. by solder weld) is not made at a pointcorresponding to the main body of the battery. As shown, the positiveelectrical connection of battery 1800 to a device to be powered may bemade at vias 1891 and 1892 formed in substrate 1890.

In embodiments of the present invention, first and second insulativepassivation layers 1860 and 1880 independently have a thickness of fromabout 1 to about 10 microns. First and second insulative passivationlayers 1860 and 1880 are independently made from an electricallyinsulating material, such as photoresist (e.g., Shipley 220 photoresist;various polyimides from HD Microsystems, such as the 2720 series, whichincludes 2727, 2723, 2729; the 2770 series which includes 2770 and 2772;the 2730 which includes 2731 and 2737; the PIX Series which includesPIX-1400, P1X-3476, PIX-S200, PIX-6400; the 2500 series, which includes2525, 2555, 2575 and 2556; and various other polymeric materials such asCyclotene product numbers 3022-35, 3022-46, 3022-57 and 3022-63 from DowChemical Company; photodefinable silicones such as WL-5351 and WL-3010from Dow Chemical Company; and UV curable epoxy such as 9001 from DymaxCorporation, or the like. In some embodiments, first and secondinsulative passivation layers 1860 and 1880 include one or morematerials such as silicon oxide, LiPON, aluminum oxide, silicon nitride,silicon oxynitride, boron nitride, ceramic, cermet, or other metaloxide, metal nitride, metal carbide, metal oxyboride, and/or metaloxynitride, wherein the metal is aluminum, indium, tin, indium-tin,zirconium, niobium, tantalum or other suitable metal, or other suitableelectrical insulator. An insulation passivation layer that is made froma material that will be self leveling for efficient planarization ispreferred. In a preferred embodiment, the insulation passivation layeris an organic material.

Conductive passivation layers as described herein, are independentlymade from conductive metals, such as from a conductive material such ascopper, aluminium, nickel, iron, gold, silver, platinum, molybdenum,manganese, metal alloys, conductive ceramics, conductive semiconductorssuch as heavily doped polycrystalline silicon, and the like. Inembodiments of the present invention, passivation layers have athickness of from about 0.11 to about 5 microns.

The battery 1800 optionally is further provided with an encapsulatingmaterial (not shown) covering the components of the battery. Inembodiments, the encapsulation is desirable in order to protect thebattery materials from exposure to water vapor, oxygen, and otherenvironmental contaminants. Lithium in particular reacts readily withother elements and compounds. Because thin film battery components inare sensitive to exposure to environmental elements, the batteryconstruction should be isolated from the outside world after productionof the battery. The final encapsulation material preferably is anorganic material as a silicone, polyimide, epoxy or other such polymeras discussed above. In an embodiment of the present invention,encapsulating material thickness is about 8 to 10 microns. In anembodiment of the present invention, a final outer layer is siliconnitride, at a thickness of about 0.5 to 1 microns, which providesadditional hermetic protection and is compatible with integrated circuitpackaging materials. This final layer also serves as something of aphysical barrier to abrasion and handling damage.

In an embodiment of the present invention, the battery 1800 providedwith a plurality of conductive passivation layers does not comprise anouter encapsulation material. This embodiment provides convenientelectrical connectivity by having an outermost conductive passivationlayer, and additionally is sufficiently environmentally protected sothat no further encapsulation material is required.

As shown, a plurality of vias are provided in substrate 1890 andinsulative passivation layer 1860. In an embodiment, only one via isprovided in either and/or both substrate 1890 and insulative passivationlayer 1860. In an embodiment, two or more vias are provided in eitherand/or both substrate 1890 and insulative passivation layer 1860.Providing a plurality of vias in either and/or both substrate 1890 andinsulative passivation layer 1860 is advantageous, because this affordsassurance of good contact in the event that one of the vias isunsatisfactory. Additionally, providing a plurality of vias in eitherand/or both substrate 1890 and insulative passivation layer 1860 isadvantageous in providing the battery configuration as shown in FIG. 14.

It will be understood that in one aspect of the invention, the batteryis built in layers as a “bottom up” construction, whereby the substrateis provided, in order, with a cathode current collector, a cathode, asolid electrolyte, an anode (which is optional during the constructionphase as discussed above), an anode current collector, and one or moreencapsulant materials. Optionally, the cathode and anode may be providedin a side by side or other configuration. Alternatively, the battery maybe constructed in the reverse order from that discussed above, so thatthe anode current collector is the located on the bottom of the batteryadjacent the substrate. This configuration is less favored in theembodiment where the anode is formed upon charging, because this anodeformation in certain embodiments will necessitate movement of most ofthe layers of the battery to accommodate formation of the anode.Alternatively, the layers may be formed separately and joined by alamination process as will now be readily envisioned by the routineer inthis art.

In an alternative embodiment, the battery may be initially preparedwithout a cathode. In this embodiment, the cathode is formed by chargingthe battery in a manner similar to the above described formation of theanode during the charging process. More specifically, by carefulselection of materials for the electrolyte and the cathode currentcollector, an anode may formed by charging the battery. For example,when the electrolyte is LiPON and the cathode current collecter issilver, it has been reported that metallic silver is oxidized to formsilver cations, which diffuse into the LiPON electrolyte and displacethe moveable lithium cations which migrate to form the metallic lithiumanode. See Liu, et al., “A ‘Lithium-Free’ Thin-Film Battery with anUnexpected Cathode Layer,” J Electrochem. Soc. 155 (1) A8-A13 (2008).

As noted above, it might be possible to custom manufacture a singlebattery having an exterior surface similar to surface 600 shown in FIGS.2 and 3 and that would have the space saving advantages of theconfigurations of the batteries described herein. However, such custommanufacture would likely be cost prohibitive and space saving advantagesapplicable with respect to the structure of device 700, for example,would not likely apply to other devices having different shapes. In abattery configuration in accordance with the present invention, however,no custom manufacture is necessary and space saving can advantageouslybe realized in devices of many different shapes and power requirement.In particular, stacking configurations can be realized using differentnumbers of batteries and different fundamental battery shapes.

In an embodiment of the present invention, the battery is fabricated ina sheet comprising multiple batteries, and the individual batteries areseparated from the sheet in a desired two-dimensional shape usingsingulation techniques such as cutting, stamping, laser cutting and thelike. Alternatively, batteries can be fabricated individually in adesired top planar view two-dimensional shape, without the need forphysical separation of the batteries by a carrier substrate.

The stacked array of thin film batteries provide advantages inmaximizing efficient use of space, and in conforming to irregularshapes. In an embodiment of the present invention, a stacked array isprovided in a battery compartment, which is a containment vessel for thebatteries. In another embodiment of the present invention an electronicdevice is provided comprising the stacked array in a batterycompartment. In another embodiment, an intermediate battery component isprovided which is a combination of the stacked array with anotherfunctional element, such as an integrated circuit that is preferablyused in combination with the battery to perform a function in anelectronic device. In another embodiment, an electronic device isprovided that comprises an intermediate battery component, which is acombination of the stacked array with another functional element, suchas an integrated circuit that is preferably used in combination with thebattery to perform a function in an electronic device.

All patents, patent applications (including provisional applications),and publications cited herein are incorporated by reference as ifindividually incorporated for all purposes. Numerous characteristics andadvantages of the invention meant to be described by this document havebeen set forth in the foregoing description. It is to be understood,however, that while particular forms or embodiments of the inventionhave been illustrated, various modifications, including modifications toshape, and arrangement of parts, and the like, can be made withoutdeparting from the spirit and scope of the invention.

1-18. (canceled)
 19. A thin film battery comprising a) a substratehaving a first surface; b) a first current collector on the firstsurface of the substrate; c) a second current collector, wherein one ofthe first and second current collector is an anode current collector andthe other is a cathode current collector; d) an electrolyte layer, theelectrolyte separating the cathode current collector from the anodecurrent collector; and e) an insulation layer, the insulation layertogether with the electrolyte layer separating the anode currentcollector from the cathode current collector; wherein the first currentcollector is exposed to provide connectivity for electrical connectionto a device to be powered by the battery through at least one via in thesubstrate, and wherein the second current collector is exposed toprovide connectivity for electrical connection to a device to be poweredby the battery through at least one via in the insulation layer.
 20. Thethin film battery of claim 19, wherein both the substrate and theinsulation layer contain two or more vias.
 21. The thin film battery ofclaim 19, wherein the substrate contains two or more vias.
 22. The thinfilm battery of claim 19, wherein the insulation layer contains two ormore vias.
 23. A plurality of thin film batteries of claim 19, whereinthe plurality of thin film batteries are electrically connected togetherand comprise at least one battery having a single surface in contactwith a plurality of batteries.
 24. The plurality of thin film batteriesof claim 23, wherein the plurality of thin film batteries are connectedin series.
 25. The plurality of thin film batteries of claim 23, whereinthe plurality of thin film batteries are connected in parallel.
 26. Theplurality of thin film batteries of claim 24, wherein the plurality ofthin film batteries are provided in a plurality of layers in a staggeredarray.
 27. The plurality of thin film batteries of claim 25, wherein theplurality of thin film batteries are provided in a plurality of layersin a staggered array.
 28. An electronic device comprising the pluralityof thin film batteries of claim 23.